Process and apparatus for treatment of fibers



Jan. 1, 1957 w. A. BEARDSELL ET AL 2,775,792

PROCESS AND APPARATUS FOR TREATMENT OF FIBERS Jan. 1, 1957 w. A. BEARDSELL ETAL 2,775,792

PROCESS AND APPARATUS FOR TREATMENT OF FIBERS 5 Sheets-Sheet 2 Filed March 31, 1953 Jan. 1, 1957 w. A. BEARDSELL ET AL 2,775,792

PROCESS AND APPARATUS FOR TREATMENT OF FIBERS 5 Sheets-Sheet 3 Filed March 51, 1953 Jan. 1, 1957 w. A. BEARDSELL ETAL 2,775,792

PROCESS AND APPARATUS FOR TREATMENT OF FIBERS 5 Sheets-Sheet 4 Filed March 31, 1953 Jan. 1, 1957 w. A. BEARDSELL ET AL 2,775,792

PROCESS AND APPARATUS FOR TREATMENT OF FIBERS Filed March 31, 1953 5 Sheets-Sheet 5 United rates Patent ice PROCESS AND APPARATUS FOR TREATMENT OF FIBERS Wallace A. Beardsell, Littleton, Walter M. Davis, Jamaica Plain, and Ralph S. Hood, Marblehead, Mass, assignors to Monsanto Chemical Company, St. Louis, Mo., a corporation of Delaware Application March 31, 1953, Serial No. 345,778

12 Claims. (Cl. 1966) The present invention relates to the application of liquids to textile fibers, particularly to webs of carded cotton fibers or webs of other carded textile fibers, for the purpose, among others, of conditioning textile fibers prior to their manufacture into rovings, yarns, fabrics or the like.

Numerous methods have ben proposed heretofore for the application of various liquids to textile fibers at various stages of the processing of such fibers prior to spinning. Thus, it has been proposed to treat an uncondensed web of cotton fibers as it moves from the card by passing such web through a housing in which the web is contacted with atomized vapor, after which the uncondensed web is condensed to form a "sliver. In carrying out such process great care must be taken to prevent air currents from contacting the uncondensed web of fibers prior to the formation of the sliver since the uncondensed web is very fragile and air currents tend to distort orv of liquid against one surface of a web of uncondensed web of fibers moving from the card "at a stage where the uncondensed web of fibers is entering a conventional trumpet in which the fibers are condensed to form a sliver. This procedure is not entirely satisfactory since the spray of droplets strikes a portion of the fibers in the uncondensed web which tends to distort or break the web and this occasionally results in the formation of a non-uniform sliver which causes difficulties in further processing operations. Moreover, this procedure does not enable the continuous uniform application of liquids to all of the fibers, and there is a definite tendency to apply too much liquid to some fibers and not enough liquid to other fibers.

It has also been proposed heretofore to apply liquids to the interior portion of a sliver as an uncondensed web of carded fibers is being condensed in a conventional trumpet. In this procedure the applicator device used includes a hollow tube which is positioned in the trumpet in such a manner that it is substantially coincident with the center of the trumpet and parallel to the direction of movement of the fibers passing through the trumpet, the orifice of the tube terminating inside of the trumpet and closely adjacent to the orifice of the trumpet. The liquid is supplied to the hollow tube !by gravity flow and is wiped from the orifice of the tube, as it drips therefrom, by the fibers as they move past the tube on their way through the orifice of the trumpet. The liquid is thus deposited in the center portion of the sliver as the sliver is formed in the trumpet. This process results in the nonuniform application of liquid to the fibers in the sliver. Thus, the fibers in the center portion of the sliver tend to be'saturated with liquid whereas the fibers on the outer surface of the sliver tend to be substantially free of liquid.

2,775,792 Patented Jan. 1, 1957 This uneven distribution of the treating liquid in the sliver is sometimes quite objectionable.

In accordance with the present invention, liquids are applied by means of 'a special device to a partially condensed web. This invention provides an improved method and apparatus to apply liquids to textile materials so that there is no distortion of the Web as it leaves the card, but provides complete penetration of the web. In accordance with this invention, the liquid is applied to a partially condensed Web preferably after it leaves the calender rolls following 'a modified trumpet. The invention will be more completely understood from the following description.

In the drawings, Fig. 1 is a diagrammatic side elevation of an apparatus, embodying the liquid applicator device of this invention; Fig. 2 is a front elevation partly in section of the apparatus shown in Fig. 1; Fig. 3 is a top plan view of the liquid applicator device; Fig. 4 is a side view of the liquid applicator device; Fig. 5 is a sectional view of the liquid applicator device with the lid attached taken on the line 5-5 of Fig. 7; Fig. 6 is a view partly in section taken on the line 6-6 of Fig. 5

. in cross seotion, by means of calender rolls 5 which also serve to compress the web of fibers.

The drawing of the uncondensed web is only carried out to the extent necessary to partially condense the fibers. The uncondensed web of fibers is thus formed into a thin, partially condensed Web 6 which is generally rectangular in crosssection and which contains at least twice as many fibers per unit of volume, for example per cubic inch, as the uncondensed web. This means that the fibers in the partially condensed web are much closer together than the fibers in the uncondensed web, and hence the partially condensed web is considerably stronger and also considerably more resistant to distortion or breakage than the uncondensed web of fibers. The partially condensed web 6 is then conveyed from the calender and drawing rolls 5 through a liquid applicator device 7 and thence over carrier roll 8. In the applicator device fine droplets of liquid are projected against the two widest surfaces of the web, that is the two surfaces of the web which have the largest area. These surfaces are on opposite sides of the web because of the generally rectangular cross-section of the web. The fine droplets of liquid are also projected in the same plane or substantially the same plane so that they strike the same longitudinal portion of the web and thus do not distort the web. After passing over the carrier roll 8, the liquid-treated, partially condensed web is conveyed to a coiler head 9 which is mounted on frame 10, and in the coiler head the web is drawnthrough a conventional trumpet 11 by means of calender rolls 12 which also serve to compress the fibers.

I In this way the partially condensed web 6 is further condensed to form a sliver, that is, a slender roll of fibers which is sufliciently strong for further processing operations such as roving, slubbing etc. The sliver is collected in a conventional container 13.

In the usual operation, prior to the present invention,

' the uncondensed web 3 was condensed directly to the silver stage by means of a conventional trumpet 11, and was not subjected to an intermediate stage of condensation 'by a modified trumpet such as trumpet 4. According to the present invention the uncondensed Web of carded fibers moving from the card is first partially condensed in modified trumpet 4, shown in Figure :2, which, rather than being circular in shape or cross-section, as is normally the case, is in an extended form in cross-section, and is generally rectangular in cross section. The partially condensed web formed by means of t umpet 4 and calender rolls 5 is considerably stronger and rnore compact, and also considerably narrower, than the uncondensed web of fibers moving from the doffer cylinder. As is pointed out above, the uncondensed web drawn through trumpet 4- and is partially condensed until it contains at least twice as many fibers per unit of volume as the uncondensed web. However, the web isf n ot condensed to the sliver stage on passage through trumpet 4 and at m Qnt q lr rt i hqn mbs ffi fibe per unit of volume as the sliver formed in trumpet 11 and collected in container 13. Thus web 6is not suff ciently strong to bee sliver. For most purposes it is preferred to condense the uncondensed web of fibers in trumpet 4 until the partially condensed web 6 has at least four times as many fibers per unit of volume as the uncondensed web 3. n n n H By partially condensing the web of fibers moving from the doffer cylinderas described above, it is possible to project fine droplets of liquid against the partially condensed web without distorting the web, and at the same timeobtain free and complete penetration of the liquid through the web without using excess liquidand without overwetting or underwetting the fibers in the web.

Referring now toFigs. 3, 4, 5, 6 and 7, showing the liquidapplicator device in greater detail, 14 is a Ll-shaped housing which may be composed of metal or other suitable material, having a cover 15 which likewise may be composed of metal or other suitable material, suitably attached by bolts 16 to brackets 48 welded to inside of housing 14. The numeral 17 is a motor supported by adjustable bracket 18. mounted on pedestal 19, welded or otherwise attached to housing 14. Motor 17 is connected to sebum- 20, which is circumscribed about drive shaft 21, by means of heavy rubber tubing 22 or other suitable means. Drive shaft 21 operating through bearing 49 and resting on ball bearing 50, is attached by key 23 to gear 24 which meshes with gears 25 for driving pumps 26, diagrammatically shown, by means of shafts 27 gears 25 resting on washers 51 and being fixed to drive shafts 27 by pins 28, and shafts 27 being supported by bearings 52. Pam as are supported by means of brackets 29 which are attached to base plate 30 and pumps 26 by screws'31. Base plate 30 is attached to housing 14 by screws 32. Pumps 26, immersed in liquid contained in tanks 53, force the liquid upwardly, through pipes 33 connected to pumps 26 by couplings 34, onto the top surfaces of centrifugals or spinners 35 in the form of flat discs'driven by air motors 36 or other means to which they are connected by drive shafts 57. The air motors 36 ahead upwardly in openings of the floor of housing 14 and are held in position by nuts 55 turning on threads 56. "Drive shafts 57 are attached to centrifugals or spinners 35 by pins 58. If air motors are employed, air under' pressure is transmitted to the air motors by tubes 47. Onthefside of'tahks 53 there are provided sight glasses 37 connected to tanks 53 by suitable couplings as, for exampl'e,'rubber stoppers 38, and may be used for adding liquid "to the tanks or for measuring the height of the liquid therein. Liquid is projected from the surfaces of.

cehtrifugals or spinners 35 in finely divided form through openings 54 in the baflling means 40 and through openings 39 in the housing 14 onto web 6 which is positioned in the open channel formed by U-shaped housing 14. Bafiling means 40, provided with openings '54 for directing the flow of the finely divided liquid on the partially condensed web 6, are supported by brackets 41 provided with threads 42. Brackets 41 extend upwardly through openings in plates 43 and through slots 44 of cover 15, and

are adjusted for horizontal motion towards or awa from the partially condensed web 6 by screws 45 connected' to plates 43 sliding in slots 44, and for rotary and vertical motion by turning on threads 42 and are locked in fixed position by nuts 46. By this means, direction and width of the flow of the stream of finely divided liquid on the web 6 are maintained. Any liquid collected on the baffles 40 and interior of the treating chambers 59 is returned to tanks 53 through suitable openings 60. Like- Wise, any liquid collected in chamber 61 may be returned to tanks 53 through opening 60 by means of drain not shown.

In the place of an air motor 36 for driving the centrifugals or spinners 35, an electric motor or other means may be employed. Also, in some cases, in place of pumps 26 for delivery of liquid under a carefully regulated flow to the centrifugals or spinners 35, other suitable carefully regulated liquid delivery devices may be employed.

The liquid is applied to the partially condensed web 6 at a point intermediate the calender rolls 5 following modified trumpet'4 and carrier roll 8 by means of the applicator device shown in the drawings forming a part of this specification. In accordance with this invention, it has been found that the web so formed is sufficiently strong so that it is not distorted by the force of the finely divided liquid and not condensed too far so that penetration by the liquid cannot be conveniently effected.

In the preferred process of the present invention, finely divided liquids are applied to both sides of the moving partially condensed web at a point intermediate calender rolls 5 and carrier roll 8. Thus, the liquid may be conveniently placed in both tanks 53 and applied to the opposite sides of the web in the manner hereinafter described.

As a specific embodiment of this invention, cotton lap of the grade of middling, staple length 1% Was run through the carding machine at the rate of 9.1 lbs/hr. and a sliver weight of 50 grains/yd, thence through the modified trumpet 4, calender rolls 5 and upwardly through the applicator device 7 and over the carrier roll 8 and finally into the container 13 as shown in Figs. 1 and 2 of the drawings. A solution comprising 84.5 parts by weight of water, 3.0 parts by weight of a commercial wetting agent which is a mixture of sodium salts of alkyl substituted benzene sulfonic acids in which the alkyl group contains from 10 to 14 carbon atoms and 12.5 parts by weight of silica in colloidal form was suitably placed in tanks 53, the pumps 26 started and air pressure applied to air motors 36 so as to drive them at a speed of 9000 R. P. M. The liquid was thereby pumped through pipes 33 onto the surfaces of centrifugals or spinners 35, driven by air motors 36, from which surface it is ejected, passing through the orifices 54 in b'afiiing means 40 and openings 39 in housing 14, in finely divided form on the opposite sides of the moving web 6, as shown in Figs. 5,6 and 7 of the drawings. The approximate rate of the solution sprayed through the'orifices in the applicator bafiles40 was 180 cc./hr. By the application of the liquid to the partially condensed Web in the manner described, the web was found to be'undisturbed and the web thoroughly penetrated with theliquid. Analysis of the treated cotton sliver showed asolids deposit of 0.306% of the total treated sliver weight. The operation was carried out continuously for extended periods of time without affecting adversely the operation of the process. Not only was very complete penetration of the partially condensed fiber efiected, but the sliver from the coilerhead was compressed tighter than normal due to the moisture added. The treated sliver was found to function in a very desirable manner when subjected to subsequent operations. In these subsequent operations, the sequence of operations and adjustments made were as follows: breaker drawing roll settings were extended /8" to accommodate the increased drag on the fibers,

otherwise the machines were operated in a normal manr st,

net. This was true at combing, finishing, drawing, slubbers, intermediate roving, and speeder or finisher roving, and spinning, where necessary; that is, the roll settings were more open than usual, but otherwise the machines were operated in the usual manner. In all cases these operations were carried out in an efiicient manner. Further, the fibers were more nearly parallel than normal and the sliver was condensed to about onehalf the diameter of untreated cotton wherever a sliver was made.

While the above specific example shows the use of the apparatus and the process of the present invention in conjunction with colloidal substances such as colloidal silica, the process and apparatus described herein may be used in the application of a large variety of liquids to textile fibers. Thus, water, oils and other liquid substances which are employed in the treatment or conditioning of textile fibers may be used instead of the solutions of colloidal silica hereinbefore described. Furthermore, if desired, textile fibers other than cotton fibers such as, for example, wool and silk fibers, and synthetic staple fibers such as rayon (regenerated cellulose) staple fibers, cellulose acetate staple fibers, nylon staple fibers, staple fibers of copolymers of vinyl chloride and vinyl acetate, staple fibers of vinylidene chloride polymers, staple fibers of acrylonitrile polymers, staple fibers of ethylene glycol-terephthalic acid polymers and the like, or various blends of such fibers, may be treated as described herein.

Again, the rate of application and the rate at which the centrifugals are rotated may be varied considerably, although it is essential that the centrifugals be revolved at sufiicient speed to uniformly distribute the liquids in the form of finely divided particles. It is to be understood that the specific examples given above are in nowise limitative, but are merely illustrative of the present invention.

The present application is a continuation-in-part of our pending application Serial No. 685,296, filed July 22, 1946, now abandoned.

What is claimed is:

l. The method of processing carded textile fibers which are produced on a card which comprises first drawing and compressing an uncondensed web of carded fibers as it moves from the card into the form of a thin, partially condensed web of generally rectangular cross-section, and continuously projecting fine droplets of liquid against the two widest surfaces of said par tially condensed web and against the same longitudinal portion of said partially condensed web, whereby said liquid completely penetrates said partially condensed web without distortion thereof.

2. The method of processing carded textile fibers which are produced on a card which comprises first drawing and compressing an uncondensed web of carded fibers as it moves from the card into the form of a thin, partially condensed web of generally rectangular cross-section, continuously projecting fine droplets of liquid against the two widest surfaces of said partially condensed web and against the same longitudinal portion of said partially condensed web, whereby said liquid completely penetrates said partially condensed web without distortion thereof, and thereafter further condensing said web of fibers until a sliver is obtained.

3. The method of processing carded textile fibers which are produced on a card which comprises first drawing and compressing an uncondensed web of carded fibers as it moves from the card into the form of a thin, partially condensed web of substantially rectangular cross-section, continuously projecting fine droplets of liquid against the two Widest surfaces of said partially condensed web and against the same longitudinal portion of said partially condensed web, whereby said liquid completely penetrates said partially condensed web without distortion thereof, and thereafter further condensing said web of fibers'until a sliver is obtained, said partially condensed web having at least twice as many fibers per unit of volume as said uncondensed web but less than one-fourth as many fibers per unit of volume as said sliver.

4. A process as in claim 3, but further characterized in that said fibers are cotton fibers.

5. A process as in claim 3, but further characterized in that said liquid is a colloidal solution.

6. A process as in claim 3, but further characterized in that the liquid is an aqueous solution of colloidal silica.

7. An apparatus for treating carded textile fibers with liquids, comprising, in combination, a U-shaped housing defining a vertical channel, means for passing a partially condensed web of carded textile fibers vertically through said channel, centrifugal means in said housing positioned on opposite sides of said channel, means for supplying a liquid to said centrifugal means and means for rotating said centrifugal means, the housing wall of said channel having openings for permitting egress of finely divided liquids from said centrifugal means to opposite sides of said web and to the same longitudinal part of the web as said web passes through said channel.

8. An apparatus according to claim 7, but further characterized in that said centrifugal means consists of horizontally positioned, rotatable, fiat discs which are mounted to rotate in the same horizontal plane.

9. An apparatus for treating carded textile fibers with liquids, comprising, in combination, a U-shaped housing defining a vertical U-shaped channel, means for passing a partially condensed Web of fibers, which web is generally rectangular in cross-section, vertically through said channel and centrally of said channel, a pair of rotatable, horizontally positioned fiat discs positioned in said housing on opposite sides of and equidistant from said channel and mounted in the same horizontal plane, means for supplying a liquid to the top surface of said discs and means for rotating said discs, said housing having openings in the walls defining said channel, which openings are directly opposite each other and are constructed to permit the egress of liquid projected from said discs toward said web of fibers.

10. An apparatus as in claim 9, but further character- -ized in that baifiing means are arranged between said discs and the openings in the housing wall to direct liquid primarily on the partially condensed web.

11. The method of processing carded cotton fibers which are produced on a card which comprises first drawing an uncondensed web of carded cotton fibers as it moves from the card through a trumpet having a thin opening which is generally rectangular in cross-section and thereafter compressing the resulting Web of fibers, whereby the web of fibers is partially condensed and is generally rectangular in cross-section, and subsequently projecting fine droplets of liquid against the two widest surfaces of said partially condensed web and against the same longitudinal portion of said partially condensed web, whereby said liquid completely penetrates said partially condensed web without distortion thereof.

12. The method of processing carded cotton fibers which are produced on a card which comprises first drawing an uncondensed web of carded cotton fibers as it moves from the card through a trumpet having a thin opening which is generally rectangular in cross-section and thereafter compressing the resulting web of fibers, said drawing and compressing of the uncondensed web being carried out to the extent that -a partially condensed web of generally rectangular cross-section is formed which contains at least twice as many fibers per unit of volume as said uncondensed Web but less than one-fourth as many fibers per unit of volume as the sliver ultimately formed from said partially condensed web, subsequently projecting fine droplets of liquid against the two widest surfaces of said partially condensed web and against the same longitudinal portion of said partially condensed web, whereby said liquid completely, penetratessaid; partially condensed'web without distortion thereof, and silhsequently further condensing said partially condensed web to form a sliver.

References Cited in the file of: this patent UNITED STATES'PATENTS 8 rDiolieet-ral, Jam-2,1934 M Ginn Aim-24, 193 Schuster Feb. 8,19% Siever Apr. 26,1938 Brandt et a1 Feb. 4, 1941 Powers June 15,- 1948 FOREIGN PATENTS Great'Britain Feb. 2, 1938 'Great' Britain Apr. 19, 1939 

